Stator Windings With 3D Printed End Turns for Interlocked Coils
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Solution Overview
Problem
Conventional winding arrangements for electric machines are limited in configuration due to the requirement of inserting conductors through the inner diameter of the stator core, restricting the design flexibility and assembly methods.
Innovation Solution
A stator with a winding arrangement featuring axial conductors in slots and 3D printed end turns that extend between pairs of conductors, forming interlocked coils, allowing for a non-radially insertable configuration and reduced electrical resistance through shorter series connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductors are inserted via the inner diameter of the stator core, then assembly is simplified, but winding configuration flexibility is limited
Solution Approach 1:
The winding arrangement is divided into axial conductors positioned in slots and separate printed end turns positioned on the end surface. This segmentation allows axial conductors to be inserted through the inner diameter while end turns are added separately to achieve complex winding configurations that would be impossible with single-piece conductors.
Solution Approach 2:
The invention transitions from traditional radial insertion only to a two-stage process: first radial insertion of axial conductors, then axial addition of printed end turns on the end surface. This dimensional approach enables complex 3D winding configurations while maintaining assembly simplicity.
2Ease of manufacture
If conventional winding arrangements are used, then assembly is easier, but electrical resistance is higher due to longer series connections
Solution Approach 1:
By segmenting the conductor into axial conductors and end turns, the series connection path is optimized. The end turns are positioned to minimize the length of series connections between coils, reducing electrical resistance while maintaining assembly simplicity.
3Adaptability or versatility
If printed end turns are used, then winding configuration flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The end turns are printed directly onto the end surface of the stator core, merging the winding formation process with the stator manufacturing process. This eliminates the need for separate conductor bending and positioning operations, reducing manufacturing complexity despite the increased winding configuration flexibility.
Solution Approach 2:
Traditional mechanical methods of forming end turns (bending, welding, positioning) are replaced with additive manufacturing (3D printing). This substitution simplifies the manufacturing process by enabling direct deposition of conductive material in the desired winding configuration.
Data Source
AI summary
A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).